SG181064A1 - Biodegradable cigarette filter tow and its process of manufacture - Google Patents
Biodegradable cigarette filter tow and its process of manufacture Download PDFInfo
- Publication number
- SG181064A1 SG181064A1 SG2012038576A SG2012038576A SG181064A1 SG 181064 A1 SG181064 A1 SG 181064A1 SG 2012038576 A SG2012038576 A SG 2012038576A SG 2012038576 A SG2012038576 A SG 2012038576A SG 181064 A1 SG181064 A1 SG 181064A1
- Authority
- SG
- Singapore
- Prior art keywords
- cellulose
- filter tow
- cellulose acetate
- cigarette
- cigarette filter
- Prior art date
Links
- 235000019504 cigarettes Nutrition 0.000 title claims abstract description 41
- 238000000034 method Methods 0.000 title claims abstract description 11
- 230000008569 process Effects 0.000 title claims abstract description 9
- 238000004519 manufacturing process Methods 0.000 title claims description 7
- 229920002301 cellulose acetate Polymers 0.000 claims abstract description 47
- 239000001913 cellulose Substances 0.000 claims abstract description 40
- 229920002678 cellulose Polymers 0.000 claims abstract description 39
- 239000002131 composite material Substances 0.000 claims abstract description 20
- 239000000203 mixture Substances 0.000 claims abstract description 15
- 238000005266 casting Methods 0.000 claims abstract description 9
- 239000002608 ionic liquid Substances 0.000 claims abstract description 9
- 238000009987 spinning Methods 0.000 claims abstract description 8
- 239000003586 protic polar solvent Substances 0.000 claims abstract description 5
- IAZDPXIOMUYVGZ-UHFFFAOYSA-N Dimethylsulphoxide Chemical compound CS(C)=O IAZDPXIOMUYVGZ-UHFFFAOYSA-N 0.000 claims description 15
- WOBHKFSMXKNTIM-UHFFFAOYSA-N Hydroxyethyl methacrylate Chemical compound CC(=C)C(=O)OCCO WOBHKFSMXKNTIM-UHFFFAOYSA-N 0.000 claims description 4
- 239000000010 aprotic solvent Substances 0.000 claims description 4
- 239000004014 plasticizer Substances 0.000 claims description 4
- 229920002239 polyacrylonitrile Polymers 0.000 claims description 4
- ZMXDDKWLCZADIW-UHFFFAOYSA-N N,N-Dimethylformamide Chemical compound CN(C)C=O ZMXDDKWLCZADIW-UHFFFAOYSA-N 0.000 claims description 3
- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 claims description 3
- 239000003054 catalyst Substances 0.000 claims description 3
- 239000000314 lubricant Substances 0.000 claims description 3
- 239000000126 substance Substances 0.000 claims description 3
- 239000012815 thermoplastic material Substances 0.000 claims description 3
- RYHBNJHYFVUHQT-UHFFFAOYSA-N 1,4-Dioxane Chemical compound C1COCCO1 RYHBNJHYFVUHQT-UHFFFAOYSA-N 0.000 claims description 2
- 239000002202 Polyethylene glycol Substances 0.000 claims description 2
- 238000004090 dissolution Methods 0.000 claims description 2
- 238000010525 oxidative degradation reaction Methods 0.000 claims description 2
- 229920000767 polyaniline Polymers 0.000 claims description 2
- 229920001223 polyethylene glycol Polymers 0.000 claims description 2
- 230000001737 promoting effect Effects 0.000 claims description 2
- LFTLOKWAGJYHHR-UHFFFAOYSA-N N-methylmorpholine N-oxide Chemical compound CN1(=O)CCOCC1 LFTLOKWAGJYHHR-UHFFFAOYSA-N 0.000 abstract 2
- 238000006065 biodegradation reaction Methods 0.000 description 6
- 239000000243 solution Substances 0.000 description 6
- URAYPUMNDPQOKB-UHFFFAOYSA-N triacetin Chemical compound CC(=O)OCC(OC(C)=O)COC(C)=O URAYPUMNDPQOKB-UHFFFAOYSA-N 0.000 description 6
- 239000000463 material Substances 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- XIYUIMLQTKODPS-UHFFFAOYSA-M 1-ethyl-3-methylimidazol-3-ium;acetate Chemical compound CC([O-])=O.CC[N+]=1C=CN(C)C=1 XIYUIMLQTKODPS-UHFFFAOYSA-M 0.000 description 4
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 230000015556 catabolic process Effects 0.000 description 4
- 238000006731 degradation reaction Methods 0.000 description 4
- -1 polypropylene Polymers 0.000 description 4
- 229920000875 Dissolving pulp Polymers 0.000 description 3
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 238000010521 absorption reaction Methods 0.000 description 3
- 230000015271 coagulation Effects 0.000 description 3
- 238000005345 coagulation Methods 0.000 description 3
- 235000013773 glyceryl triacetate Nutrition 0.000 description 3
- 239000001087 glyceryl triacetate Substances 0.000 description 3
- RAXXELZNTBOGNW-UHFFFAOYSA-N imidazole Natural products C1=CNC=N1 RAXXELZNTBOGNW-UHFFFAOYSA-N 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 229960002622 triacetin Drugs 0.000 description 3
- FHDQNOXQSTVAIC-UHFFFAOYSA-M 1-butyl-3-methylimidazol-3-ium;chloride Chemical compound [Cl-].CCCCN1C=C[N+](C)=C1 FHDQNOXQSTVAIC-UHFFFAOYSA-M 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 239000004372 Polyvinyl alcohol Substances 0.000 description 2
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 2
- KAESVJOAVNADME-UHFFFAOYSA-N Pyrrole Chemical compound C=1C=CNC=1 KAESVJOAVNADME-UHFFFAOYSA-N 0.000 description 2
- 238000013459 approach Methods 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 2
- 229920002988 biodegradable polymer Polymers 0.000 description 2
- 239000004621 biodegradable polymer Substances 0.000 description 2
- 229920001222 biopolymer Polymers 0.000 description 2
- 238000002788 crimping Methods 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 230000036541 health Effects 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 239000002480 mineral oil Substances 0.000 description 2
- 229920002451 polyvinyl alcohol Polymers 0.000 description 2
- 235000019422 polyvinyl alcohol Nutrition 0.000 description 2
- 230000001376 precipitating effect Effects 0.000 description 2
- 230000001172 regenerating effect Effects 0.000 description 2
- SNICXCGAKADSCV-JTQLQIEISA-N (-)-Nicotine Chemical compound CN1CCC[C@H]1C1=CC=CN=C1 SNICXCGAKADSCV-JTQLQIEISA-N 0.000 description 1
- PFZPMLROUDTELO-UHFFFAOYSA-N 1-methyl-1h-imidazol-1-ium;acetate Chemical compound CC(O)=O.CN1C=CN=C1 PFZPMLROUDTELO-UHFFFAOYSA-N 0.000 description 1
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- QPLDLSVMHZLSFG-UHFFFAOYSA-N Copper oxide Chemical class [Cu]=O QPLDLSVMHZLSFG-UHFFFAOYSA-N 0.000 description 1
- 244000061176 Nicotiana tabacum Species 0.000 description 1
- 235000002637 Nicotiana tabacum Nutrition 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000004146 Propane-1,2-diol Substances 0.000 description 1
- 229920000297 Rayon Polymers 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 1
- FZWLAAWBMGSTSO-UHFFFAOYSA-N Thiazole Chemical compound C1=CSC=N1 FZWLAAWBMGSTSO-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 150000001450 anions Chemical class 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 150000007942 carboxylates Chemical class 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 150000001805 chlorine compounds Chemical class 0.000 description 1
- 150000001879 copper Chemical class 0.000 description 1
- 238000000578 dry spinning Methods 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 239000003995 emulsifying agent Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000013538 functional additive Substances 0.000 description 1
- 229910052736 halogen Inorganic materials 0.000 description 1
- 150000002367 halogens Chemical class 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
- 238000006460 hydrolysis reaction Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 229910001510 metal chloride Inorganic materials 0.000 description 1
- 235000010446 mineral oil Nutrition 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 229960002715 nicotine Drugs 0.000 description 1
- SNICXCGAKADSCV-UHFFFAOYSA-N nicotine Natural products CN1CCCC1C1=CC=CN=C1 SNICXCGAKADSCV-UHFFFAOYSA-N 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- 239000005014 poly(hydroxyalkanoate) Substances 0.000 description 1
- 229920000903 polyhydroxyalkanoate Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 235000013772 propylene glycol Nutrition 0.000 description 1
- 229960004063 propylene glycol Drugs 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
- 230000000391 smoking effect Effects 0.000 description 1
- 239000002195 soluble material Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 229920003179 starch-based polymer Polymers 0.000 description 1
- 239000004628 starch-based polymer Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 229910021653 sulphate ion Inorganic materials 0.000 description 1
- 239000003053 toxin Substances 0.000 description 1
- 231100000765 toxin Toxicity 0.000 description 1
- 108700012359 toxins Proteins 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 238000002166 wet spinning Methods 0.000 description 1
Classifications
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
- A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
- A24D3/06—Use of materials for tobacco smoke filters
- A24D3/067—Use of materials for tobacco smoke filters characterised by functional properties
- A24D3/068—Biodegradable or disintegrable
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/02—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from cellulose, cellulose derivatives, or proteins
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
- A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
- A24D3/02—Manufacture of tobacco smoke filters
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
- A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
- A24D3/06—Use of materials for tobacco smoke filters
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
- A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
- A24D3/06—Use of materials for tobacco smoke filters
- A24D3/08—Use of materials for tobacco smoke filters of organic materials as carrier or major constituent
- A24D3/10—Use of materials for tobacco smoke filters of organic materials as carrier or major constituent of cellulose or cellulose derivatives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/05—Filamentary, e.g. strands
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
- D01F2/02—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof from solutions of cellulose in acids, bases or salts
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
- D01F2/24—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof from cellulose derivatives
- D01F2/28—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof from cellulose derivatives from organic cellulose esters or ethers, e.g. cellulose acetate
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Textile Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Biodiversity & Conservation Biology (AREA)
- Mechanical Engineering (AREA)
- Artificial Filaments (AREA)
- Cigarettes, Filters, And Manufacturing Of Filters (AREA)
- Multicomponent Fibers (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
- Woven Fabrics (AREA)
- Materials For Medical Uses (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
Abstract
The present invention concerns a biodegradable cigarette filter tow comprising composite filaments of cellulose and cellulose acetate, and a process for making such a filter tow comprising providing a solution dope comprising a blend of cellulose and cellulose acetate in an ionic liquid or in N-methylmorpholine-N-oxide (NMMO), and spinning casting the blend into a protic solvent to generate fibres or films, and converting the fibres or films into cigarette filter tow. The invention also concerns cigarette filters and cigarettes made from such a filter tow.
Description
BIODEGRADABLE CIGARETTE FILTER TOW
AND ITS PROCESS OF MANUFACTURE
The present invention concerns biodegradable composite materials, especially for use in cigarette filter tows.
The first cigarette filters were developed in the 1920s and were composed of crepe paper, sometimes together with cellulose wadding. Subsequent concerns over the adverse link between smoking and health led to a surge in demand for filters yielding lower tar levels. A dual filter comprising cellulose acetate fibres within a paper sheath was developed, allowing for the addition of other functional components such as activated carbon.
Further concerns over health, increased legislation and market pressures for reduced tar, nicotine and carbon monoxide levels require continued development in filter technology. Today the global market for cigarettes exceeds 5.8 trillion sticks per annum, 97% of which now contain filters. Of the filtered cigarettes 80.4% are made from standard cellulose acetate fibre (4.5 trillion sticks), 16.6% are classed as ‘special’ filters and 3% are made from polypropylene.
Typically cigarette filters comprise a “filter tow”, generally crimped fibres of cellulose acetate, encased in a tipping paper. This invention is concerned with the filter tow component.
One of the most pressing issues for manufacturers of cigarettes and cigarette filters is the rate at which the filters biodegrade. Cellulose acetate filters can take between one month and three years to biodegrade, dependant on environmental conditions, which is not sufficiently fast to avoid the issue of litter. Discarded cigarette filters top the list of almost all coastal clean-up surveys. The issue of litter is not just a visual one, the toxins adsorbed by used cigarette filters have been found to leach into the environment, and present a potential biohazard.
A range of approaches to the preparation of biodegradable filter tow have been suggested and include the use of composites of cellulose acetate with other biodegradable polymers, additives for increasing the rate of degradation of cellulose acetate, cellulose acetate with a low degree of substitution (DS) for increased biodegradability, and biodegradable polymers such as PHB/PVB and starches as the filter tow raw material.
However, to date no satisfactory commercial solution has been found for producing consumer-acceptable filters that degrade sufficiently quickly to overcome the issue of litter. One main restriction to the above approaches has been achieving an acceptable compromise between the rate of biodegradability that can be achieved and the absorption profile / taste signature given by the filter material.
The present invention seeks to address these problems.
According to the present invention there is provided a biodegradable cigarette filter tow comprising composite filaments of cellulose and cellulose acetate.
Cellulose and cellulose acetate are typically cast in the form of fibres or films.
Either form of casting is suitable for preparing the biodegradable cigarette filter tows of the invention. When cast in the form of films it is necessary then to shred the resulting film to produce material suitable for cigarette filter tows.
Preferred filter tows in accordance with the invention comprise fibres spun from a coagulated solution of cellulose and cellulose acetate.
Reference herein to composite filaments of cellulose/cellulose acetate shall be understood to mean either fibres spun from a dope comprising cellulose and cellulose acetate, or shredded films cast from similarly constituted dope.
We have found that composite filaments of celiulose/cellulose acetate have significantly greater biodegradability than equivalent filaments comprising only cellulose or cellulose acetate. Without wishing to be bound by any such theory, we believe that the presence of acetate in the composite may disrupt the crystallinity of the cellulose, causing it to biodegrade more rapidly than cellulose itself.
Conventionally, cellulose is cast or spun from viscose, and it is difficult or impossible to cast or spin cellulose acetate from the same blend because of the likelihood of hydrolysis of the cellulose acetate under such conditions.
Conversely, cellulose acetate is conventionally cast or spun from acetone and it is difficult or impossible to cast or spin cellulose from the same blend because of the limited solubility of cellulose in acetone.
However, we have found that by casting or spinning cellulose and cellulose acetate from an ionic liquid (IL) or from N-methylmorphilone-N-oxide (NMMO), it is possible to form spun fibres and cast films comprising a composite blend of these materials. The enhanced biodegradability of such composites and their suitability for use in cigarette filter tow manufacture has not previously been recognised.
Consequently, the cigarette filter tow of the invention is preferably formed from fibres or films of cellulose and cellulose acetate spun or cast as a blend from an ionic liquid (IL) or from N-methylmorphilone-N-oxide (NMMO).
The use of ILs and NMMO for dissolving cellulose and other polymers has been well documented, for example in US20050288484 and US 20070006774 of the University of Alabama, US20080188636 of the North
Carolina State University and W02005098546 of Holbrey et al. A wide range of ionic liquids, including those disclosed in the aforesaid publications, are suitable for dissolving cellulose and cellulose acetate and for casting as blends fibres or films therefrom. General types of suitable IL include those based on imidazole, pyrrole, thiazole or pyrazole cations in combination with halogen, phosphate, carboxylate or metal chloride anions. Particularly preferred ILs include 1-butyl-3-methylimidazolium chloride (BMIM-CI) 1-butyl- _4-
3-methylimidazolium acetate (BMIM-Ac) and 1-ethyl-3-methylimidazolium acetate (EMIM-Ac).
The solution of cellulose and cellulose acetate from which fibres are spun or films are cast is referred to herein as a dope. The dope may also comprise an aprotic solvent such as DMSO, DMF, THF or dioxane to aid dissolution of the cellulose and/or cellulose acetate. One particularly preferred aprotic solvent is
DMSO.
The blend of cellulose acetate and cellulose in the dope may also comprise one or more further thermoplastic materials, such as polyhydroxyalkanoates such as PHB and/or PHVB which may add further functionality, such as water barrier functionality, to the cigarette filter tows of the invention. Other functional additives may include triacetin, polyacrylonitrile (PAN), poly-2- hydroxyethylmethylacrylate (PHEMA), polyvinylalcohol (PVA), polyaniline and polyethylene glycol for functional purposes such as modification of absorption and/or taste profile, degradation enhancement (by, for example, water-soluble materials), and processability improvement, in connection for example with wet strength. (Triacetin may improve taste profile, as well as acting as a plasticiser.)
The weight ratio of cellulose to cellulose acetate in the dope, and consequently in the cigarette filter tow of the invention is from 10:90 to 90:10, for example from 20:80 to 80:20, or from 30:70 to 70:30.
Typically, the dope comprises a solids content of up to about 50% w/w, preferably up to about 40% w/w, more preferably up to about 30% w/w and most preferably up to about 20% w/w.
The filter tows of the invention may additionally comprise one or more plasticisers, such as triacetin, which may aid crimping of the composite filaments. In the cigarette filter tow of the invention the composite filaments of cellulose/cellulose acetate are preferably crimped to provide smoke barrier contact points. The plasticiser may be included in the dope, or may added subsequent to spinning or casting, for example by spraying onto the surface of the filter tow before or during crimping.
The filter tows of the invention may additionally comprise a catalyst promoting oxidative degradation of the filter tow. Suitable catalysts include iron and copper oxides and chlorides, which may be introduced into the tow by immersing the composite filaments in an aqueous solution of a water-soluble iron or copper salt, such as sulphate or chloride, and precipitating the oxide (preferably in nano-form) onto or into the filament by treatment with sodium hydroxide or other suitable precipitating agent.
The tows may also comprise one or more lubricants to reduce electrostatic charge. Preferred lubricants include mineral oils. For example, 1% w/w of mineral oil with an emulsifier may be applied to the composite filaments during spinning of the fibres or casting of the films.
Preferably the filter tows of the invention comprise composite filaments of cellulosel/cellulose acetate manufactured at 1, 5 or 9 denier per filament (filament thickness (denier per filament) being defined as the mass (grams) of 9000 m of a single uncrimped filament).
The total tow mass (total denier) (defined as the total mass of 9000 m of uncrimped filter tow, typically comprising many thousands, for example 11,000, individual fibres) will vary considerably depending on the methods employed in fibre spinning and the number of individual fibres in the tow. One typical tow mass would 35,0009.
Preferably the filter tows of the invention comprise fibres having a ftrilobal filament cross-section (optionally formed using triangular spinneret holes) to optimise surface area.
The filter tows of the invention preferably comprise crimped fibres, the crimp structure defined by the crimp index, which is the ratio between stretched (25 kg load) and unstretched (0.25 kg load) filter tow. The crimp index will vary considerably depending on the precise method of manufacture.
The moisture content of the cigarette filter tows according to the invention is preferably at least about 2% w/w, more preferably at least about 5% wiw, even more preferably at least about 10% w/w. Moisture content has been found to be important for preventing electrical charges, but should preferably not be too high (e.g. not higher than 50% w/w) because with a very high moisture content it may be difficult for the tow to retain a crimp.
The filter tows of the invention preferably comprise entangled filaments.
Also provided in accordance with the invention is a cigarette filter comprising the cigarette filter tow as hereinbefore described encased in a tipping wrapper.
Preferably the tipping wrapper is itself a biodegradable substance and may for example comprise paper or an alternative biodegradable substrate such as cellulose, PLA, hydroxyalkanoates, a starch based polymer, or other form of biopolymer.
When the tipping wrapper comprises a biopolymer, it preferably comprises a softener in an amount of not more than about 25% by weight to achieve suitable properties particularly in connection with elongation and tube curl.
The softener may in the biopolymeric tipping wrapper may be selected from any suitable material, but is preferably selected from glycerol, propane-1,2- diol, and any other suitable softener selected from the German Tobacco
Ordnance (TVO) list.
Also provided in accordance with the invention is a cigarette comprising a smokable substance and a cigarette filter as hereinbefore described.
Also provided in accordance with the invention is a process for manufacturing cigarette filter tow comprising providing a solution comprising a blend of cellulose and cellulose acetate in an ionic liquid or in NMMO, and spinning or casting the blend into a protic solvent to generate fibres or films, and converting the fibres or films into cigarette filter tow.
Water is the preferred protic solvent for the regenerative casting of the blend.
In the process of the invention, composite cellulose / cellulose acetate materials can be produced at any ratio by regenerating solutions in water and / or other protic solvents. The rate of coagulation in water has been found to be dependant on the cellulose acetate content of the dope, where increased levels of cellulose acetate reduce the rate of coagulation.
The invention will now be more particularly described in the Examples which follow and which make reference to the following drawings:
Figure 1 shows three slides showing fibres of i) cellulose acetate; ii) cellulose; and iii) a blend of cellulose and cellulose acetate in accordance with the invention.
Figure 2 shows the slides of Figure 1 after 2 weeks biodegradation under anaerobic conditions.
Figure 3 shows the slides of Figure 1 after 4 weeks biodegradation under anaerobic conditions.
Figure 4 shows the slides of Figure 1 after 6 weeks biodegradation under anaerobic conditions.
Example 1
The biodegradability of wet-spun fibres of blended cellulose/cellulose acetate was assessed in comparison with equivalent wet-spun fibres of cellulose, and equivalent wet-spun fibres of cellulose acetate.
Using standard wet-spinning equipment fibres were spun from solutions of i) cellulose (DP ~800) and ii) 1:1 cellulose: cellulose acetate (Eastman, CA-398- 30), at 10 % solids in EMIM-Ac: DMSO (20:80). A 40-orifice spinneret with an orifice diameter of 70 ym was used, which was submerged in a room temperature coagulation bath containing clean water. The fibres were reeled- up wet, extensively washed on the reel then dried at 50 °C.
With reference to Figures 1 to 4, a surprising property of these composite materials is that the rate of biodegradation under anaerobic environments exceeds that of cellulose and greatly exceeds that of cellulose acetate under the same conditions (see appendix 1). It is thought (although this theory is in no way to be considered binding) that the two components form an intimately mixed composite and that the enhanced rate of degradation arises from a reduction in the crystallinity of the cellulose. Degradation of the cellulose component of the composite is thought to lead to the cellulose acetate component being deposited on a molecular scale. We have also found that the rate of biodegradation under aerobic conditions of the cigarette filter tows in accordance with the invention is similarly improved.
The application of these composite materials in the manufacture of cigarette filter tow offers a route to achieving a product with both the desired absorption profile / taste signature achieved by using cellulose acetate alone, but with greatly increased rates of biodegradation.
Example 2
Filter tow according to the invention is manufactured using a dry-spinning process. A dope is first prepared by dissolving cellulose diacetate and cellulose (1:1 blend) at 10 % solids in EMIM-Ac: DMSO (20:80). TiO, is added to give a whitened appearance. The dope is then filtered and spun into chambers, causing the filaments to solidify and become thinner. More than 10,000 filaments are spun from a series of spinning cabinets, which are combined to form a single band. A stuffer box is used to emboss the filter tow with a crimp structure, and the resulting filter tow is encased in a tipping paper to form a cigarette filter.
The resulting cigarette filter is found to retain to advantageous biodegradability properties as shown in Example 1 and to have an acceptable taste signature.
Claims (14)
1. A biodegradable cigarette filter tow comprising composite filaments of cellulose and cellulose acetate.
2. A filter tow according to claim 1 further comprising one or more further thermoplastic materials.
3. A filter tow according to claim 2 wherein the further thermoplastic material is selected from one or more of PHB, PHVB, polyacrylonitrile (PAN), poly-2-hydroxyethylmethylacrylate (PHEMA), polyvinylaicohol (PVA), polyaniline and polyethylene glycol.
4. A filter tow according to any one of claims 1 to 3 wherein the weight ratio of cellulose to cellulose acetate is from 10:90 to 90:10.
5. A filter tow according to claim 4 wherein the ratio of cellulose to cellulose acetate is from 20:80 to 80:20.
6. A filter tow according to claim 5 wherein the ratio of cellulose to cellulose acetate is from 30:70 to 70:30.
7. Afilter tow according to any one of claims 1 to 6 further comprising one or more plasticisers.
8. A filter tow according to any one of claims 1 to 7 further comprising a catalyst promoting oxidative degradation of the filter tow.
9. Afilter tow according to any one of claims 1 to 8 further comprising one or more lubricants to reduce electrostatic charge on the tow.
10. A cigarette filter comprising the cigarette filter tow according to any one of claims 1 to 9 encased in a tipping wrapper.
11.A cigarette comprising a smokable substance and a cigarette filter according to claim 10.
12.A process for manufacturing a cigarette filter tow according to any one of claims 1 to 9 comprising providing a solution dope comprising a blend of cellulose and cellulose acetate in an ionic liquid or in N- methylmorphilone-N-oxide (NMMO), and spinning or casting the blend into a protic solvent to generate fibres or films, and converting the fibres or films into cigarette filter tow.
13. A process according to claim 12 wherein the dope further comprises an aprotic solvent to aid dissolution of the cellulose and/or cellulose acetate.
14.A process according to claim 13 wherein the aprotic solvent comprises one or more of DMSO, DMF, THF or dioxane.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB0918633A GB2474694B (en) | 2009-10-23 | 2009-10-23 | Biodegradable composites |
PCT/GB2010/051562 WO2011048397A1 (en) | 2009-10-23 | 2010-09-17 | Biodegradable cigarette filter tow and its process of manufacture |
Publications (1)
Publication Number | Publication Date |
---|---|
SG181064A1 true SG181064A1 (en) | 2012-07-30 |
Family
ID=41426623
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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SG2012038576A SG181064A1 (en) | 2009-10-23 | 2010-09-17 | Biodegradable cigarette filter tow and its process of manufacture |
Country Status (20)
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US (4) | US8833376B2 (en) |
EP (2) | EP2490557B1 (en) |
JP (3) | JP5944317B2 (en) |
KR (1) | KR101818559B1 (en) |
CN (4) | CN105342004A (en) |
BR (2) | BR112012009307A2 (en) |
CY (1) | CY1117628T1 (en) |
ES (2) | ES2532147T3 (en) |
GB (1) | GB2474694B (en) |
HK (1) | HK1217157A1 (en) |
HR (1) | HRP20160504T1 (en) |
HU (2) | HUE025084T2 (en) |
MX (1) | MX2012004043A (en) |
MY (1) | MY182730A (en) |
PL (2) | PL2490557T3 (en) |
PT (2) | PT2490557E (en) |
RS (1) | RS54787B1 (en) |
SG (1) | SG181064A1 (en) |
SI (1) | SI2491172T1 (en) |
WO (2) | WO2011048397A1 (en) |
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2009
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